Earth-boring tools and components thereof including material having hard phase in a metallic binder, and metallic binder compositions for use in forming such tools and components

Patent metadata

Field	Value
Publication number	US-9428822-B2
Application number	US-201313847282-A
Country	US
Kind code	B2
Filing date	Mar 19, 2013
Priority date	Apr 28, 2004
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

Binder compositions for use in forming a bit body of an earth-boring bit include at least one of cobalt, nickel, and iron, and at least one melting point-reducing constituent selected from at least one of a transition metal carbide up to 60 weight percent, a transition metal boride up to 60 weight percent, and a transition metal silicide up to 60 weight percent, wherein the weight percentages are based on the total weight of the binder. Earth-boring bit bodies include a cemented tungsten carbide material comprising tungsten carbide and a metallic binder, wherein the tungsten carbide comprises greater than 75 volume percent of the cemented tungsten carbide material.

First claim

What is claimed is:

1. A body of an earth-boring tool, comprising hard particles in a binder material, the hard particles comprising a transition metal carbide, the binder material comprising a eutectic or near-eutectic composition of the transition metal carbide and at least one of cobalt, iron, and nickel, wherein the transition metal carbide comprises greater than 75 volume percent of the body.

2. The body of claim 1 , wherein some of the transition metal carbide is comprised of the hard particles and some of the transition metal carbide is comprised of the binder material.

3. The body of claim 1 , wherein the body is at least substantially comprised of the hard particles and the binder material.

4. The body of claim 1 , wherein the body comprises a bit body of an earth-boring rotary drill bit.

5. A body of an earth-boring tool, comprising hard particles in a binder material, the hard particles comprising tungsten carbide, the binder material comprising a eutectic or near-eutectic composition of the tungsten carbide and at least one of cobalt, iron, and nickel.

6. The body of claim 5 , wherein the eutectic or near-eutectic composition comprises a eutectic or near-eutectic composition of tungsten carbide and cobalt.

7. The body of claim 5 , wherein the body is at least substantially comprised of the hard particles and the binder material.

8. The body of claim 5 , wherein the body comprises a bit body of an earth-boring rotary drill bit.

9. A cast body of an earth-boring tool, comprising a composite material having a microstructure including a hard ceramic phase and a metal phase, wherein the hard ceramic phase comprises at least 75 percent by volume of the composite material, and wherein at least a portion of the composite material is formed from a eutectic or near-eutectic composition.

10. The cast body of claim 9 , wherein the composite material includes hard particles dispersed within a binder.

11. The cast body of claim 10 , wherein some of the hard ceramic phase is comprised of the hard particles and some of the hard ceramic phase is formed from the eutectic or near-eutectic composition.

12. The cast body of claim 9 , wherein the hard ceramic phase comprises a transition metal carbide.

13. The cast body of claim 12 , wherein the transition metal carbide comprises tungsten carbide.

14. The cast body of claim 12 , wherein the eutectic or near-eutectic composition comprises a eutectic or near-eutectic composition of the transition metal carbide and at least one of cobalt, iron, and nickel.

15. The cast body of claim 14 , wherein the eutectic or near-eutectic composition comprises a eutectic or near-eutectic composition of tungsten carbide and cobalt.

16. The cast body of claim 15 , wherein the metal phase comprises the cobalt.

17. The cast body of claim 9 , wherein the cast body is at least substantially comprised of the composite material.

18. The cast body of claim 9 , wherein the cast body comprises a bit body of an earth-boring rotary drill bit.

Assignees

• Baker Hughes Inc
• Tdy Ind Llc
• Tdy Ind Inc

Inventors

• Mirchandani Prakash K
• Eason Jimmy W
• Oakes James J
• Westhoff James C
• Collins Gabriel B

Classifications

• C22C1/1047

  by mixing and casting liquid metal matrix composites · CPC title

• C22C1/1036

  starting from a melt · CPC title

• B22F1/12

  Metallic powder containing non-metallic particles (containing lubricating or binding agents or organic material B22F1/10) · CPC title

• E21B10/62

  characterised by parts, e.g. cutting elements, which are detachable or adjustable (E21B10/64 takes precedence; for roller bits E21B10/20; for augers E21B10/44) · CPC title

• E21B10/567

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title